Eagle mike piston kit installation - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 13 Old 08-11-2019, 08:39 PM Thread Starter
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Eagle mike piston kit installation

Hi!, let me introduce my self, my name is francisco, im from Guatemala and i recently bought a supposedly 16k miles klr 05.

I saw a post on the internet and it was quite cheap, but it was kind of far from where i live so i asked an uncle to buy it for me. So he did, but didnt pay much atenttion to some certain detailes, like the fact that never got a service on time which lead me to making just the oil change when i first got it and then i tought it would be ok for the next 2 or 3k miles.

But, surprise!! it was burning oil, and it got consumed pretty quickly, which caused it to began making some nocking on the engine bay.

After i realized about that, i wanted to try something before accepting i was gonna have to change various internal parts , so i made a full service and schedule the next one on the 1k miles mark. When i reach the milleage and drained the oil, i just got a little bit over 600 ml.

It was then when i started to think about a way to fix it and try not to spend a huge amount of money, due to the fact that i cant get spare parts for the bike in the "away from all civilization country" i live in. And stumbled upon various piston kits from eagle mike that went from 685 cc all the way to up to the 719 ccs.

Now, i have the money and a way to get it, for another uncle of mine, which happens to live in arizona and its in his disposition to buy that kit and all the parts i need for the bike and send them to me.

The only problem i have is that i dont even know what parts i am supposed to buy, i mean, i should get the piston kit, but then what else? new valves? and if a get the new valves, should i get the shims?

Also, i know the doohickey its the weak spot of the bike, so i also like to buy one of those kits, as well as a stiffer spring for the rear, a progressive spring for the forks and try to keep it in the 1k price range for all i want.

I would really appreciate if somebody could give me an advise on how to do it, even more, have some patience on me due to my total unknowledge about this.

Pd: i totally hope i expressed myself properly, i havent yet perfectioned my english.
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post #2 of 13 Old 08-15-2019, 09:29 AM
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Sorry that there has been no response to your post.

Like you say yourself - I dont know what parts I am supposed to buy.

At this point I would say not to buy anything. You could be throwing your hard earned money away.

Engine noise can result from a number if issues. First thing you have to do is to tear down the engine to determine the problem. You may find internal damage that would make it unfeasible to investment in repairing it. Sounds like the person you bought it from knew it had issues and was looking to dump it quickly.

Good luck and keep us informed with your progress. Sorry this happened to you.

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 13 Old 08-15-2019, 09:38 AM
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Reading your post again concerns me. Getting only 600ml of oil out when changing it is not good. You need to check the level on the sight glass regularly.

You have likely starved the top end of oil which will result in camshaft and head damage. Easiest first step is to remove the valve cover and inspect the camshaft and head. If there is damage it will be very expensive to repair, especially in your part of the world. Used heads are very hard to find.

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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Last edited by klr4evr; 08-15-2019 at 09:45 AM.
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post #4 of 13 Old 08-15-2019, 10:19 AM
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I'll suggest that by running your engine down to that low of oil quantity even once for even 5 minutes of run time, that the cylinder head camshaft bearings have been severely damaged, therefore the knocking.

Useable used cylinder heads are extremely hard to find for Exactly this reason. Too many owners neglect to check their oil level daily! The oil burning may have been caused by a melted hole in the bottom of the air box allowing un-filtered air to enter or by lack of properly Oiling a freshly cleaned air filter.

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post #5 of 13 Old 08-15-2019, 02:24 PM
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Ya thats correct - USEABLE heads are almost nonexistent. I should have stipulated that.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #6 of 13 Old 08-15-2019, 02:43 PM Thread Starter
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Ill be taking apart my engine in the next few days , anyways, i might not be able to determine if the cylinder heads are still useable.

Is it any body willing to help in the process of fixing my bike. Thats right what i need, some advise in order to get things straight again.

Last edited by francisco ortiz; 08-15-2019 at 03:16 PM.
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post #7 of 13 Old 08-16-2019, 08:34 AM
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There are lots of folks that will assist you with advice. If your head is damaged it doesn’t take too much experience to see it. Surfaces should be smooth. When you have melted and gouged metal you’ll see it. Do you have a repair manual to assist you in taking it apart? A mechanically inclined friend?? You can find a lot of info on You Tube too.

When you take it apart take lots of pictures. You can’t post pictures on the site until you have 15 posts but we can work around that.

Good luck with your disassembly.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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Last edited by klr4evr; 08-16-2019 at 08:36 AM.
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post #8 of 13 Old 08-16-2019, 02:48 PM Thread Starter
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I took my bike yesterday to my trust mechanic, and he took apart my engine.

He called me and told me that he had already done it, and that he will be seeing me today.

I went today with him, he showed me my engine, or what it was left and after gettting pretty anxious about it, i found out that it was in quite a well shape.

The previously owner totally knew the engine was failing and tried to fix it, to which he did not succeed. The piston was covered in oil all the way to the top. The cylinder head was, well, ill show you a picture.

So far, i guess ill be able to install an oversized piston as i was initially planning, but id like to hear your comnents.

as i cant yet post any image or url, if theres any body willing to see the pictures of my engine, i uploaded them to flickr, so all you have to do is enter flickr page, then add a (/) after the (.com), and then copy and paste what i just put below.

photos/[email protected]/with/48553442716/

Last edited by francisco ortiz; 08-16-2019 at 02:50 PM. Reason: i didnt put some important info
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post #9 of 13 Old 08-16-2019, 03:45 PM
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post #10 of 13 Old 08-16-2019, 06:05 PM Thread Starter
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Thank you Dan filipi
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engine replacement, engine upgrade, oil user, piston kit, suspension mods

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